JP6688903B2 - Electrical connector with two-piece cavity insert - Google Patents

Description

  The subject matter herein relates generally to connector assemblies. Radio frequency (RF) connector assemblies have been used for numerous applications, including military and automotive applications, such as Global Positioning System (GPS), antennas, radios, mobile phones, multimedia devices. . The connector assembly is typically a coaxial cable connector provided at the end of a coaxial cable.

Certain industry standards have been established to standardize various types of connector assemblies, and particularly interfaces to such connector assemblies. One of these standards is called FAKRA, which is an abbreviation for the German word Fachnormenausschuss Kraftfahrzeugindustrie. FAKRA is the Automotive Standards Committee within the German Standards Organization and represents the benefits of international standardization in the automotive sector. The FAKRA standard provides a system based on keying and color coding for proper connector attachment. Within the FAKRA connector, only unique jack keys can be connected to similar plug keyways.
A FAKRA defined stop surface located on the jack or housing of the first assembly and a cooperating latch located on the housing of the plug or second assembly facilitates secure positioning and locking of the connector housing.

  Connector assemblies typically include a housing having a mating interface for mating with a mating connector. The housing holds a contact assembly that electrically connects to a corresponding mating contact of the mating connector. Cavity inserts in a contact assembly typically secure the contact assembly within the housing so that the contact assembly does not disengage when the mating connector is mated to or unmated from the housing. Used for. The cavity insert is an adapter that engages both the outer contacts of the contact assembly and the inner portion of the housing. The cavity insert allows the contact assembly to fit into a variety of different housings.

Typically, the cavity insert is cylindrical and is mounted over the outer contact by sliding the cavity insert over the end of the outer contact. For example, the cavity insert can be mounted over the rear end of the outer contact, which has a smaller diameter than the front end of the outer contact. However, for some connectors, slipping the cavity insert over the end of the outer contact may not be feasible, or at least not desirable. For example, some known outer contacts are configured to electrically connect to a relatively large cable at the rear end of the outer contact, so that the rear end of the outer contact may not be received in the cavity insert. Can be too big.
Due to spacing limitations within the housing, it may not be possible to make the cavity insert large to accommodate the large rear end of the outer contact. In addition, some known outer contacts are formed on the carrier strip, allowing the contact assembly to be assembled while the outer contacts remain attached to the carrier strip. Even if the trailing end of the outer contact is small enough to be received within the cavity insert, the trailing end may still be secured to the carrier strip, which prevents the cavity insert from being mounted over the trailing end.

A solution to this problem is provided by the electrical connector disclosed herein that is capable of accommodating various outer contacts while complying with space limitations within the housing and any applicable industry standard specifications. The electrical connector includes outer contacts and a cavity insert. The outer contact has a mating portion, a terminating portion, and an intermediate portion located between the mating portion and the terminating portion. The mating portion is configured to engage the mating contact of the mating connector. The termination is configured to electrically connect to the cable. The cavity insert defines a channel that receives the outer contact. The cavity insert surrounds the middle portion of the outer contact. The cavity insert is defined by an upper shell and a lower shell joined together at the interface.
The upper shell extends along a portion of the circumference of the outer contact and the lower shell extends along the remaining portion of the circumference of the outer contact. The upper shell includes a first strap extending across the interface. The first strap includes a catch surface that engages a corresponding first stop surface of the lower shell to couple the upper shell to the lower shell.
The first stop surface projects outwardly from the channel from a planar region formed on the outer surface of the lower shell parallel to the connecting axis (298) of the upper shell and the lower shell.
The first strap is cantilevered and defines an opening between the inner surface and the outer surface, the latching surface being the distal wall of the opening proximate the free end of the first strap.

  The invention will now be described by way of example with reference to the accompanying drawings.

FIG. 6 illustrates a connector system formed according to an exemplary embodiment. FIG. 3 is an exploded view of a female connector and cable of the connector system according to one embodiment. FIG. 6 is a perspective exploded view of a contact assembly for a female connector according to one embodiment. FIG. 6 is a side perspective view of a contact assembly in an assembled state according to one embodiment. FIG. 5 is an exploded cross-sectional view of the cavity insert of the female connector taken along line 5-5 shown in FIG. 2. Figure 5 is an assembled cross-sectional view of the cavity insert and outer contact taken along line 5-5. FIG. 9 is a cross-sectional view of a portion of an assembled cavity insert according to an alternative embodiment.

  One or more embodiments described herein disclose a connector system that includes a first connector and a second connector. At least one of the first connector or the second connector includes an outer contact and a cavity insert surrounding the outer contact. A cavity insert extends between the outer contact and the outer housing of the connector to secure the outer contact (and any components located within and / or coupled to the outer contact) to the outer housing. Hold in position. The cavity insert has a two-piece structure formed from two shells joined together to define the cavity insert. The two shells are moved towards each other and are joined together with the outer contacts located between the two shells. Therefore, the cavity insert is not axially mounted over the end of the outer contact to surround the outer contact.

  The two shells are connected to each other by a latching device. The latching device includes at least one strap extending from one shell toward the other shell and a stop surface located on the other shell and engaging a latching surface of the strap. The latching device can include a plurality of straps and corresponding stop surfaces. Optionally, each shell can be amphoteric and includes both at least one stop surface and at least one hanging strap. In one embodiment, the locking components of each shell (eg, the locking straps and the locking surfaces) are integrally formed with the respective shell, such as during the molding process. Moreover, the two shells can have the same shape as each other, and thus the same mold or process can be used to form both shells, which are joined to form the cavity insert. .

  As used herein, the term "surrounding" means extending around the periphery of another object in at least one dimension, such as surrounding an object along a portion of the length of the object. As used herein, the term "surrounding" does not necessarily require that the enclosed object be completely enclosed or packaged by surrounding the object in all dimensions.

FIG. 1 illustrates a connector system 100 formed according to an exemplary embodiment. Connector system 100 includes a first electrical connector 102 and a second electrical connector 104 that are configured to mate together and transmit electrical signals between each other. In the illustrated embodiment, the first electrical connector 102 is a male connector and the second electrical connector 104 is a female connector, so that during the mating operation, a portion of the first electrical connector 102 will have a second electrical connector. Received within the cavity 106 of the connector 104. More specifically, the male housing 108 (eg, conical head) of the first connector 102 is received within the cavity 106 defined by the female housing 110 of the female connector 104.
Although not shown in FIG. 1 in a fitted state, the first connector 102 and the second connector 104 are in a state in which they can be fitted along the fitting shaft 112. In this specification, the first electrical connector 102 is referred to as the male connector 102 or the mating connector 102, and the second electrical connector 104 is referred to as the female connector 104 or simply the connector 104.

  The connector system 100 may be used to electrically couple two or more devices and / or electrical components in numerous applications across a variety of industries such as the automotive industry, the consumer electronics industry, the aircraft industry, and the like. You can For example, in the automotive industry, electrical connectors 102, 104 may be used for radio frequency communication, electrically connecting antennas to controllers and / or processing devices, and the like.

The male connector 102 and the female connector 104 are each electrically connected to different electrical components to provide a conductive path between corresponding electrical components. In the illustrated embodiment, male connector 102 and female connector 104 are electrically connected to corresponding conductive cables or wires 114, 116, such as coaxial cables. In alternative embodiments, male connector 102 and / or female connector 104 may be attached to a corresponding circuit board (eg, edge mount). The cable 114 is electrically terminated (eg, crimped, soldered, etc.) to the electrical contacts of the male connector 102. The cable 116 is electrically terminated to the electrical contacts of the female connector 104.
The electrical contacts of the male connector 102 engage the electrical contacts of the female connector 104 when the connectors 102, 104 are mated. Various electrical signals carrying power, control messages, data, etc. may be transmitted between the cables 114 and 116 through the connectors 102, 104.

  In the illustrated embodiment, both male connector 102 and female connector 104 have an in-line configuration. For example, the mating shaft 112 into which the male connector 102 is inserted into the cavity 106 is substantially parallel to the orientation of the cable 114 exiting the male connector 102 and the cable 116 exiting the female connector 104. In alternative embodiments, male connector 102 and / or female connector 104 may also have a right-angled shape.

  In the illustrated embodiment, male connector 102 and female connector 104 comprise a FAKRA connector, which is an RF connector with an interface that conforms to the standards for uniform connector system established by the FAKRA Automotive Expert Group. FAKRA connectors have standardized keying and locking systems that meet the high functionality and safety requirements of automotive applications. FAKRA connectors are based on microminiature B connectors (SMB connectors) featuring snap-on couplings designed to operate at characteristic impedances such as 50, 75, 93, and / or 125 ohms. Connector system 100 may also utilize other types of connectors other than the FAKRA connectors described herein.

During mating, the front end 126 of the male connector 102 is moved along the mating axis 112 and inserted through the front end 128 of the female connector 104 into the cavity 106 of the female connector 104. Relative or spatial terms such as “front”, “rear”, “top”, or “bottom” are used herein only to distinguish the referenced elements, and of the connector system 100. It does not necessarily require a particular position or orientation with respect to the surrounding environment. The male connector 102 has one or more keying features 118 and the female connector 104 has one or more keying features 120 that are complementary to the keying features 118 of the male connector 102. In the illustrated embodiment, the keying mechanism 118 is a rib and the keying mechanism 120 is a channel that receives the rib 118. Any number of keying mechanisms 118, 120 can be provided.
The keying mechanism 118, 120 can be part of the standardized design of the FAKRA connector. For example, the keying rib 118 and the keying channel 120 can be configured to limit mating of each connector 102, 104 with one or more unique mating connectors.

  The male connector 102 holds the mating connection between the two connectors 102, 104 (by limiting undesired unmating of the connectors 102, 104) to provide a complementary locking mechanism 124 for the female connector 104. Has a latching mechanism 122 configured to engage. In the illustrated embodiment, the latching mechanism 122 is a stop face and the latching mechanism 124 is a flexible latch that engages the stop face 122 when the connectors 102, 104 are mated together. Latch 124 is configured to be lifted or pivoted over stop surface 122 to disconnect male connector 102 and female connector 104.

  FIG. 2 is an exploded view of female connector 104 and cable 116 according to one embodiment. Female connector 104 includes a female housing 110 (also referred to herein as outer housing 110) and a contact assembly 130. The contact assembly 130 is retained within the outer housing 110. Contact assembly 130 includes central contact 132, dielectric 134, outer contact 136, cavity insert 138, and optional ferrule 140. In other embodiments, female connector 104 may include one or more additional components and / or may not include all of the described components.

  Cable 116 may be a coaxial cable having a central conductor 170 (eg, one or more wires) surrounded by a dielectric layer 172. A cable braid 174 surrounds the dielectric layer 172. The cable braid 174 provides shielding for the central conductor 170 along the length of the cable 116. A cable jacket 176 surrounds the cable braid 174 and provides protection to the cable braid 174, dielectric layer 172, and center conductor 170 from external forces and contaminants. The cable 116 is configured to electrically connect to the contact assembly 130 via crimping, soldering, or the like.

  In the illustrated embodiment, the central contact 132 of the contact assembly 130 comprises a socket contact configured to receive and electrically engage the pin contacts of the male connector 102 (shown in FIG. 1). Alternatively, the central contact 132 can be a pin contact or another type of contact. The center contact 132 is composed of a conductive material such as one or more metals. The center contact 132 is terminated to the center conductor 170 of the cable 116, such as by crimping.

  A dielectric 134 surrounds the central contact 132. For example, the dielectric 134 defines a passage 142 that receives the central contact 132. Dielectric 134 is composed of a dielectric material such as one or more plastics. The dielectric 134 is configured to extend between the central contact 132 and the outer contact 136 to electrically insulate the two contacts 132, 136 from each other.

  Outer contact 136 surrounds dielectric 134 and central contact 132 located within dielectric 134. Outer contact 136 is composed of a conductive material such as one or more metals. Outer contact 136 provides central contact 132 with shielding, such as from electromagnetic or radio frequency interference. Outer contact 136 is configured to electrically connect to cable braid 174 of cable 116.

  Outer contact 136 extends between front end 144 and rear end 146 and defines a chamber 148 extending through outer contact 136 between front end 144 and rear end 146. The dielectric 134 is received within the chamber 148 and the cable 116 terminated at the central contact 132 projects from the rear end 146 of the outer contact 136. The outer contact 136 has a substantially cylindrical shape or a barrel shape. In one embodiment, the outer contacts 136 are stamped and formed into a cylindrical shape by stamping a sheet of metal and then rolling.

The outer contact 136 includes a mating portion 150 extending rearward from the front end 144 and a terminal end portion 152 extending forward from the rear end 146. The mating portion 150 is configured to engage an outer mating contact (not shown) of a mating connector such as the male connector 102 (shown in FIG. 1). The mating portion 150 includes one or more retention features 154, such as flexible beams, protrusions, barbs, etc., for maintaining engagement between the mating portion 150 of the outer contact 136 and the outer mating contact. be able to. Termination portion 152 is configured to electrically connect to cable braid 174 of cable 116. For example, the cable braid 174 can surround the termination 152 and can be crimped to the termination 152 via the ferrule 140. Optionally, outer contact 136 can include an intermediate portion 156 between the mating portion 150 and the end portion 152 along the length of the outer contact 136.
The middle portion 156 can have a different diameter than at least one of the mating portion 150 and the end portion 152. For example, in the illustrated embodiment, the middle portion 156 has a diameter that is smaller than the mating portion 150 and larger than the end portion 152. Outer contact 136 is stepped along its length to define at least first step 158 and second step 160. The first step 158 separates the mating portion 150 from the middle portion 156. The second stage 160 separates the middle section 156 from the termination section 152. In alternative embodiments, the terminating portion 152 can have a larger diameter than the middle portion 150, such as when the terminating portion 152 is configured to electrically connect to a cable that is larger than the cable 116.

Cavity insert 138 surrounds at least a portion of outer contact 136. Cavity insert 138 extends between leading end 162 and trailing end 164 and defines a channel 166 extending through cavity insert 138 between leading end 162 and trailing end 164. Outer contact 136 is retained within channel 166. In one embodiment, the cavity insert 138 surrounds the middle portion 156 of the outer contact 136 so that the inner surface 168 of the cavity insert 138 engages the middle portion 156. The cavity insert 138 can optionally surround at least a portion of the mating portion 150 and / or the terminating portion 152. The inner surface 168 of the cavity insert 138 can engage the first step 158 and / or the second step 160. Cavity insert 138 is configured to axially secure outer contact 136 within channel 166 such that outer contact 136 is axially immovable with respect to cavity insert 138.
Cavity insert 138 optionally prevents outer contact 136 from rotating relative to cavity insert 138. Cavity insert 138 is an adapter configured to engage outer housing 110 to retain contact assembly 130 in a fixed axial position within cavity 106 of housing 110. For example, cavity insert 138 can include at least one flange 186 that extends circumferentially along the perimeter of cavity insert 138. Flange 186 is configured to engage outer housing 110 within cavity 106 to secure the axial position of contact assembly 130.

  The ferrule 140 is configured to crimp over the cable 116 to the terminal end 152 of the outer contact 136. Ferrule 140 provides electrical termination of braid 174 to outer contact 136 and strain relief to cable 116. In the exemplary embodiment, ferrule 140 is configured to crimp both cable braid 174 and cable jacket 176 of cable 116.

  The female outer housing 110 extends between a front end 128 and a rear end 129. The outer housing 110 has a substantially box-shaped outer profile. The cavity 106 of the outer housing 110 can be a generally cylindrical hole extending through the outer housing 110. Cavity 106 can have steps, shoulders, and / or channels configured to engage and secure cavity insert 138 within cavity 106.

  In one embodiment, the outer housing 110 is configured to receive a retention clip 182 that extends through an opening in a sidewall 184 of the housing 110. Retaining clip 182 is configured to be inserted into housing 110 following contact assembly 130 to secure contact assembly 130 to housing 110. For example, the retaining clip 182 can engage one or more flanges 186 of the cavity insert 138 to secure the axial position of the contact assembly 130 within the cavity 106.

  Although the female connector 104 is shown and described in FIG. 2, the male connector 102 (shown in FIG. 1) may also have components that are similar and / or identical to those of the female connector 104. For example, male connector 102 can include a contact assembly received within male housing 108 (shown in FIG. 1). The contact assembly of the male connector 102 can include a central contact, a dielectric, an outer contact, and a cavity insert that are at least similar to the components of the contact assembly 130 described in FIG. For example, male connector 102 can include a cavity insert similar to cavity insert 138 of female connector 104 shown and described below.

  In one embodiment, the cavity insert 138 is formed from a two piece structure that includes a first shell 188 and a second shell 190. The first shell 188 and the second shell 190 are separate pieces that are joined together and define a cavity insert 138. For example, the first shell 188 extends along a portion of the outer contact 136 perimeter and the second shell 190 extends along the remaining portion of the outer contact 136 perimeter. The first shell 188 and the second shell 190 engage one another at the interface 194 to form the assembled intact cavity insert 138 shown in FIG.

FIG. 3 is a perspective exploded view of the contact assembly 130 of the female connector 104 according to one embodiment. In the illustrated embodiment, the central contact 132 (shown in FIG. 2) within the dielectric 134 is not visible. Contact assembly 130 is oriented with respect to vertical or elevation axis 191, lateral axis 193, and mating axis 112. The axes 191, 193, 112 are orthogonal to each other. Although the elevation axis 191 appears to extend substantially parallel to gravity, it is understood that the axes 191, 193, 112 need not have any particular orientation to gravity. In FIG. 3, the first shell 188 extends above the outer contact 136 (along the vertical axis 191) and the second shell 190 is located below the outer contact 136. The first shell 188 is referred to herein as the upper shell 188 and the second shell 190 is referred to as the lower shell 190.
As mentioned above, the terms "top" and "bottom" are used only to distinguish the referenced elements and do not necessarily require a particular position or orientation of the female connector 104 relative to the surrounding environment. . Therefore, when the contact assembly 130 is rotated 180 degrees, the upper shell 188 may be located below the lower shell 190.

Optionally, outer contact 136 is connected to metal carrier strip 196 when cavity insert 138 is assembled around outer contact 136. The end portion 152 of the outer contact 136 is mechanically connected to the carrier strip 196. Because the carrier strip 196 is connected to the end 152, the pre-assembled cavity insert 138 cannot be received over the end 152 to surround the outer contact 136. The channel 166 of the cavity insert 138 (shown in FIG. 2) may be smaller in diameter than the mating portion 150, and therefore the cavity insert 138 may not be mounted over the mating portion 150. Therefore, the pre-assembled cavity insert 138 should not be able to surround the outer contact 136.
In the illustrated embodiment, the cavity insert 138 has a two-piece construction so that the cavity insert 138 can be assembled around the outer contact 136. For example, the cavity insert 138 is assembled in situ around the outer contact 136 so that the outer contact 136 is positioned between the two shells 188, 190 when the two shells 188, 190 are joined together.

Optionally, each of upper shell 188 and lower shell 190 can be connected to a respective plastic carrier strip 198. Carrier strip 198 includes links 200 extending outwardly from respective shells 188, 190 along transverse axis 193. The link 200 may be separated from the shell 188, 190 before or after the shell 188, 190 surrounds the outer contact 136 and is coupled to each other. In one embodiment, each shell 188, 190 is constructed of a dielectric material such as one or more plastics. The shells 188, 190 can be formed by a molding process. The carrier strip 198 can be formed with the respective shells 188, 190 during the same molding process.
In one embodiment, the upper shell 188 has an integral body 202 and the lower shell 190 has an integral body 204. Accordingly, the latching mechanism located on the upper shell 188 and lower shell 190 used to connect the shells 188, 190 together may be integrally formed on the respective body 202, 204 of the shells 188, 190. Alternatively, after forming the shells 188, 190, one or more latching features or other components may be attached to the corresponding shells 188, 190 via bonding, gluing, fastening, etc.

The body 202 of the upper shell 188 is curved between the first edge 206 and the second edge 208. The first edge 206 is laterally spaced from the second edge 208. The upper shell 188 extends longitudinally along the mating axis 112 between the front end 210 and the rear end 212. First edge 206 and second edge 208 extend between a front end 210 and a rear end 212 over the length of upper shell 188. Curved body 202 includes an inner surface 214 and an outer surface 216. Inner surface 214 defines a portion of channel 166 (shown in FIG. 2) when cavity insert 138 is assembled. The outer surface 216 defines a portion of the outer circumference of the assembled cavity insert 138.
In one embodiment, the body 202 of the upper shell 188 defines approximately one half of the outer circumference of the assembled cavity insert 138, while in other embodiments it is greater than one half of the outer circumference of the cavity insert 138. Or a small portion can be defined. In the orientation shown in FIG. 3, the body 202 has a convex curve with respect to the link 200 extending from the body 202 so that the body 202 arcs upward from the edges 206, 208.

The upper shell 188 includes latching components used to connect the upper shell 188 to the lower shell 190. For example, in the illustrated embodiment, the upper shell 188 includes a strap 218 that extends beyond the first edge 206 of the upper shell 188 toward the lower shell 190. The strap 218 extends generally vertically downward from the first edge 206. The strap 218 includes a hooking surface 220 configured to engage a corresponding stop surface 284 of the lower shell 190 to couple the upper shell 188 to the lower shell 190. The upper shell 188 also includes a plurality of stop surfaces 222 that are spaced along the length of the upper shell 188. Each stop surface 222 is configured to engage a catch surface 250 of a corresponding strap 248 of the lower shell 190.
In the illustrated embodiment, the upper shell 188 includes a first stop surface 222A proximate the front end 210, a second stop surface 222B proximate the rear end 212, and an axial first stop surface 222B. It includes three stop surfaces 222 including a third stop surface 222C disposed between 222A and the second stop surface 222B. All three stop surfaces 222A-C are located along the outer surface 216 and proximate the second edge 208 of the upper shell 188. In alternative embodiments, the top shell 188 may also include other than three stop surfaces 222 proximate the second edge 208.

  In the illustrated embodiment, the stop surface 222 of the upper shell 188 is defined by the hook surface of each tab 224 that projects radially outward from the outer surface 216. The tabs 224 can be aligned with corresponding flange portions 226 that define a portion of the flange 186 (shown in FIG. 2) of the assembled cavity insert 138. The outer surface 216 of the upper shell 188 can include one or more planar areas 228 proximate the second edge 208. The outer surface 216 is flat or flat along the planar region 228 rather than being curved. The stop surface 222 is arranged along the plane area 228. For example, the tab 224 projects radially outward from the planar region 228 of the outer surface 216.

The body 204 of the lower shell 190 is curved between a first edge 236 and a second edge 238 that are laterally spaced from each other. The lower shell 190 extends longitudinally along the mating axis 112 between a front end 240 and a rear end 242. First edge 236 and second edge 238 extend the length of lower shell 190 between front end 240 and rear end 242. Curved body 204 includes an inner surface 244 and an outer surface 246. Inner surface 244 defines a portion of channel 166 (shown in FIG. 2) and inner surface 214 of upper shell 188 defines the remainder of channel 166 when cavity insert 138 is assembled. The outer surface 246 defines a portion of the outer circumference of the assembled cavity insert 138, and thus the outer surfaces 216, 246 of the upper shell 188 and lower shell 190 define the entire outer circumference of the cavity insert 138.
In the orientation shown in FIG. 3, the body 204 has a concave curve with respect to the link 200 extending from the body 204 so that the body 204 arcs downward from the edges 236, 238.

The lower shell 190 includes latching components used to connect the lower shell 190 to the upper shell 188. For example, in the illustrated embodiment, the lower shell 190 includes a plurality of straps 248 that extend beyond the first edge 236 of the lower shell 190 toward the upper shell 188. The strap 248 extends generally vertically upward from the first edge 236. The straps 248 each include a latching surface 250 configured to engage a corresponding stop surface 222 of the upper shell 188 to couple the upper shell 188 and the lower shell 190. In the illustrated embodiment, the lower shell 190 includes a first strap 248A proximate the front end 240, a second strap 248B proximate the rear end 242, and an axial first strap 248A and a second strap 248A. Includes three straps 248 including a second strap 248B and a third strap 248C disposed therebetween.
The latching surfaces 250 of the first strap 248A, the second strap 248B, and the third strap 248C, when the shells 188, 190 are coupled, are similar to the first stop surface 222A, the second stop of the upper shell 188. Aligns and engages surface 222B and third stop surface 222C, respectively. All three straps 248A-C of the lower shell 190 are located along (extend from) the first edge 236 of the lower shell 190. In alternative embodiments, the lower shell 190 may also include a total of more than three straps 248 and / or other than three straps 248 along the first edge 236.

The straps 248A-C can have the same or similar size and shape as each other. Each strap 248 is a cantilever beam or limb that projects beyond or from the first edge 236 to a respective free end 252. The strap 248 is at least semi-rigid so that the strap 248 is capable of flexing elastically back toward its initial rest position when the flexing force on the strap 248 is removed. Each strap 248 includes an inner surface 254 that faces the channel 166 (shown in FIG. 2) and an opposite outer surface 256 that faces outwardly from the channel 166. The inner surface 254 can be substantially flat and the outer surface 256 can be curved. In one embodiment, each strap 248 defines an opening 258 extending through the respective strap 248 between the inner surface 254 and the outer surface 256.
Opening 258 is defined along a portion of strap 248 that extends beyond first edge 236. Latching surface 250 is the distal wall of opening 258. Distal wall 250 is proximate to free end 252 of each strap 248. Distal wall 250 can be oriented generally vertically downward and / or toward first edge 236 from which strap 248 extends. In an alternative embodiment, the openings 258 are recesses or depressions defined along the inner surface 254 of the strap 248 rather than completely penetrating the respective strap 248. In such an alternative embodiment, the latching surface 250 can be the distal wall of the recess.

Although not shown in FIG. 3, in one embodiment, the lower shell 190 includes at least one stop surface 284 (shown in FIG. 4) extending from the outer surface 246 proximate the second edge 238. Stop surface 284 can be similar in shape, size, and / or mechanism to stop surface 222 of upper shell 188. Additionally, although only partially visible in FIG. 3, the strap 218 of the upper shell 188 is optionally substantially similar in shape, size, and / or mechanism to the strap 248 of the lower shell 190. Can be In one embodiment, both the upper shell 188 and the lower shell 190 are amphoteric, thus each shell 188, 190 includes at least one stop surface and at least one strap including a hooking surface.
In alternative embodiments, the shells 188, 190 are not amphoteric, so the upper shell 188 includes only the straps 218 or only the stop surfaces 222, the lower shell 190 includes only the plurality of stop surfaces 284 or only the plurality of straps 248, etc. , Including only complementary locking mechanism.

As shown in FIG. 3, straps 218, 248 of upper shell 188 and lower shell 190, respectively, are disposed along first edges 206, 236 of shells 188, 190, respectively. The straps 218, 248 do not lie along their respective second edges 208, 238. Further, each stop surface 222, 284 (shown in FIG. 4) is located proximate the second edge 208, 238 of the shell 188, 190, but proximate the first edge 206, 236. I haven't. However, in one or more alternative embodiments, the top shell 188 includes at least one strap 218 disposed along each of the first edge 206 and the second edge 208, and / or the first shell 218. It may also include at least one stop surface 222 proximate each of the edge 206 and the second edge 208.
Similarly, in an alternative embodiment, the lower shell 190 includes at least one strap 248 disposed along each of the first edge 236 and the second edge 238, and / or the first edge 236 and It may also include at least one stop surface 284 proximate each of the second edges 238.

In one embodiment, upper shell 188 and lower shell 190 have the same shape. For example, the size, contour, and features of the upper shell 188 are the same as the size, contour, and features of the lower shell 190. Upper shell 188 and lower shell 190 may be formed through the same process, such as by forming the same or the same process. Therefore, both the upper shell 188 and the lower shell 190 can be formed using only a single mold, which can reduce the manufacturing cost. In the illustrated embodiment, the lower shell 190 is oriented 180 degrees with respect to the upper shell 188 about the mating axis 112. For example, because upper shell 188 is identical to lower shell 190, strap 218 of upper shell 188, which can be seen in FIG. 3, is the same as first strap 248A of lower shell 190.
As used herein, the use of the term “identical” refers to imperfections, defects, and other minor irregularities in which one or both shells 188, 190 are not shared by both shells 188, 190 (eg, (Due to the manufacturing process or subsequent handling).

As shown in FIG. 3, the outer contact 136 may include a protrusion 260 that extends radially outward from the middle portion 156 of the outer contact 136. The lower shell 190 defines a recess 262 along the inner surface 244. Recess 262 receives protrusion 260 when upper shell 188 and lower shell 190 are mated to secure outer contact 136 within cavity insert 138. As shown in FIG. 3, the lower shell 190 defines two recesses 262, one recess 262 proximate a first edge 236 and the other recess 262 a second edge 238. Is close to. In the illustrated embodiment, based on the orientation of the outer contact 136 and the lower shell 190, a protrusion 260 is received within the recess 262 proximate the first edge 236 and another protrusion of the middle portion 156. (Not shown) can be received in the other recess 262 proximate the second edge 238.
Receiving the protrusions 260 in the corresponding recesses 262 allows the outer contacts 136 to be locked or secured axially and rotationally relative to the cavity insert 138. Although not shown, the top shell 188 can define one or more indentations that interface with the indentation 262 to define a larger recess. In an alternative embodiment, the intermediate portion 156 can define a recess and the cavity insert 138 can include a protrusion configured to extend into the recess. In addition, the cavity insert 138 may engage the outer contact 136 through engagement with the first step 158 and / or the second step 160 of the outer contact 136 or one or more other portions of the outer contact 136. The axial position can be fixed.

FIG. 4 is a side perspective view of the contact assembly 130 in an assembled state according to one embodiment. In FIG. 4, the cavity insert 138 has been completed so that the upper shell 188 is coupled to the lower shell 190 and surrounds the outer contact 136. The illustrated embodiment of the cavity insert 138 differs slightly from the embodiment shown in FIG. 3 because the cavity insert 138 includes only two latching features along the length of the cavity insert 138 instead of three. Cavity insert 138 extends between front end 264 and rear end 266. The front end 264 is defined by the front end 210 of the upper shell 188 and the front end 240 of the lower shell 190. The rear end 266 is defined by the rear ends 212, 242 of the upper shell 188 and the lower shell 190, respectively. In the illustrated embodiment, the upper shell 188 includes a first strap 218A proximate the front end 264 of the cavity insert 138 and a second strap 218B proximate the rear end 266.
The second strap 218B is the same or similar to the first strap 218A. Both straps 218A, 218B extend across an interface 194 defined between shells 188, 190 to engage corresponding stop surfaces 284A, 284B of lower shell 190. The interface 194 between the shells 188, 190 defines a first seam 268 between the first edge 206 of the upper shell 188 and the second edge 238 of the lower shell 190. The first seam 268 extends the length of the cavity insert 138. Straps 218A, 218B extend across the first seam 268. The straps 218A, 218B overlap the portion of the outer surface 246 of the lower shell 190 proximate the stop surfaces 284A, 284B. Although not visible in FIG. 4, interface 194 also extends a second length 208 of cavity insert 138 between second edge 208 of upper shell 188 and first edge 236 of lower shell 190. Of seams 270 (shown in FIG. 6).

  5 is an exploded cross-sectional view of cavity insert 138 taken along line 5-5 shown in FIG. The upper shell 188 is ready to be joined to the lower shell 190. In the illustrated embodiment, the curved body 202 of the upper shell 188 has a first shoulder 272 located at the first edge 206 and a second shoulder 274 located at the second edge 208. Including. The shoulders 272, 274 are generally flat surfaces extending inwardly from the respective edges 206, 208. The strap 218 of the upper shell 188 is located proximate to the first shoulder 272 and extends beyond the first shoulder 272. In the illustrated embodiment, the strap 218 is disposed outward from the shoulder 272, so the shoulder 272 extends inward from the edge 206 and the strap 218 extends outward from the edge 206. The stop surface 222 of the upper shell 188 is located along the planar region 228 of the outer surface 216 proximate the second shoulder 274.

  The strap 218 extends from a fixed end 276 located on the body 202 to the free end 302. The fixed end 276 can be located at the first edge 206 or can be spaced from the first edge 206 along the perimeter of the outer surface 216 of the upper shell 188. The strap 218 defines an opening 278 extending through the strap 218. The opening 278 is similar to the opening 258 that extends through the strap 248 of the lower shell 190. The opening 278 can be defined between the tip 280 of the strap 218 and the first edge 206. The tip 280 includes a free end 302. The tip 280 also includes a latching surface 220. For example, the latching surface 220 can be the distal wall of the opening 278.

  The stop surface 222 of the upper shell 188 is the hook surface of the tab 224 that projects outwardly from the outer surface 216. In one embodiment, hook surface 222 can have an acute angle with planar area 228 above tab 224. For example, hook surface 222 is beveled to extend along vertical axis 191 at least slightly away from edge 208. In an alternative embodiment, hook surface 222 can extend orthogonal to planar area 228. In the illustrated embodiment, the tab 224 includes a beveled surface 282 that slopes outwardly away from the planar region 228 of the outer surface 216 as the distance from the second edge 208 increases. In the illustrated embodiment, the beveled surface 282 extends from the second edge 208, but in other embodiments the tab 224 can be spaced from the edge 208. The hook surface 222 is located opposite the tab 224 with respect to the beveled surface 282.

  The curved body 204 of the lower shell 190 includes a first shoulder 292 located at the first edge 236 and a second shoulder 294 located at the second edge 238. The shoulders 292, 294 are generally flat surfaces extending inwardly from the respective edges 236, 238. The strap 248 of the lower shell 190 is located proximate the first shoulder 292 and extends beyond the first shoulder 292. The stop surface 284 of the lower shell 190 is located proximate the second shoulder 294 and along the planar area 286 of the outer surface 246.

  In the illustrated embodiment, the lower shell 190 is identical to the upper shell 188. For example, the lower shell 190 shown in FIG. 5 should be aligned with the upper shell 188 when the lower shell 190 is rotated 180 degrees clockwise (or counterclockwise). Therefore, the hooking mechanism of the lower shell 190 has the same shape as the hooking mechanism of the upper shell 188 and will not be described in detail herein. For example, strap 248 can be the same as strap 218 and stop surface 284 can be the hook surface of tab 296 that is the same as tab 224.

To join the upper shell 188 and the lower shell 190, the shells 188, 190 are moved towards each other along the joining axis 298. The distal end 302 of the strap 218 of the upper shell 188 moves along and / or parallel to the planar area 286 of the lower shell 190 and engages the beveled surface 300 of the tab 296. The strap 218 slides along the tab 296 and flexes radially outwardly from the natural rest position of the strap 218 shown in FIG. Distal end 302 slides along tab 296 until latching surface 220 passes hook surface 284 of tab 296. After the hooking surface 220 has passed the hook surface 284, the tab 296 is allowed to elastically move radially inward toward the natural rest position of the strap 218.
Meanwhile, the distal end 252 of the strap 248 engages the bevel 282 of the tab 224 and flexes around the tab 224 in the same manner as the strap 218 engages and flexes around the tab 296.

FIG. 6 is an assembled cross-sectional view of cavity insert 138 and outer contact 136 taken along line 5-5. In the assembled state, the first edge 206 of the upper shell 188 is aligned with the second edge 238 of the lower shell 190 and the latching surface 220 of the strap 218 engages the hook surface 284 of the tab 296. To meet. Further, the second edge 208 of the upper shell 188 is aligned with the first edge 236 of the lower shell 190, and the latching surface 250 of the strap 248 engages the hook surface 222 of the tab 224. Optionally, there may be a slight gap between the hooking surface 220, 250 and the corresponding hook surface 222, 284. The first shoulder 272 of the upper shell 188 can engage opposite the second shoulder 294 of the lower shell 190, and the second shoulder 274 of the upper shell 188 can engage the second shoulder 274 of the lower shell 190. One shoulder 292 can be engaged opposite.
Optionally, there may be a slight gap 306 between the shoulders 272, 274 of the upper shell 188 and the corresponding shoulders 294, 292 of the lower shell 190. The interface 194 can be defined between the shoulders 272, 274, 292, 294. For example, the first seam 268 of the interface 194 is defined between the shoulder 272 and the shoulder 294, and the second seam 270 is defined between the shoulder 274 and the shoulder 292. The strap 218 extends from the upper shell 188 across the first seam 268 and engages a tab 296 on the lower shell 190. The strap 248 extends from the lower shell 190 across the second seam 270 and engages the tab 224 of the upper shell 188.

As shown in FIG. 6, outer contact 136 is disposed within channel 166 of cavity insert 138. In one embodiment, the outer contacts 136 can support the assembled state of the cavity insert 138 by providing internal support to the inner surface 168 of the cavity insert 138. In the illustrated embodiment, without the internal support of the outer contacts 136, the upper shell 188 is slid in one direction 310 and the lower shell 190 is slid in the opposite direction 312 to move the upper shell 188 into the lower shell. It is no longer possible to decouple from 190.
Thus, the cavity insert 138 can be configured to allow the cavity insert 138 to be disassembled if the outer contact 136 is not within the channel 166 or has a diameter that is too small for the channel 166, and the contact assembly It can be ensured that 130 (shown in Figure 2) is properly assembled.

  FIG. 7 is a cross-sectional view of a portion of an assembled cavity insert 138 according to an alternative embodiment. FIG. 7 shows the latching surface 250 of the strap 248 of the lower shell 190 coupled to the retaining surface 222 of the upper shell 188. However, stop surface 222 is not the hook surface of a tab that projects outwardly from outer surface 216, and in the illustrated embodiment stop surface 222 is the wall of a recess 316 defined along outer surface 216. The wall 222 extends inwardly from the outer surface 216 toward the channel 166 (shown in FIG. 6). In the illustrated embodiment, the latching surface 250 of the strap 248 is the hook surface of the tab 318 that projects from the inner surface 320 of the strap 248. The hook surface generally faces the fixed end 322 of the strap 248 and / or the first edge 236 of the lower shell 190. The tab 318 extends into the recess 316 when the upper shell 188 and the lower shell 190 are joined.

  It should be understood that the above description is intended to be illustrative rather than limiting. For example, the above-described embodiments (and / or aspects thereof) can be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. The dimensions, types of materials, orientations of various components, and the numbers and locations of various components described herein are intended to define parameters for particular embodiments, and are not meant to be limiting. Rather, it is merely an exemplary embodiment. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reading the above description. Accordingly, the scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims (8)

An outer contact (136) having a mating portion (150), a terminating portion (152) and an intermediate portion (156) located between the mating portion (150) and the terminating portion (152), An outer contact (136), wherein the mating portion is configured to engage a mating contact of a mating connector (102) and the termination portion is configured to electrically connect to a cable (116). ,
Comprising a, a cavity insert (138) defining a channel (166) receiving said outer contact,
The cavity insert surrounds the middle portion of the outer contact, the cavity insert being defined by an upper shell (188) and a lower shell (190) joined together at an interface (194), the upper shell comprising: A first strap (218) extends along a portion of the periphery of the outer contact, the lower shell extends along the remainder of the periphery of the outer contact, and the upper shell extends across the interface. wherein, said first strap, seen including a latching surface (220) of said engaged with the corresponding first stop surface of the lower shell (284) for coupling said upper shell to the lower shell,
The first stop surface (284) is a flat area formed on the outer surface (246) of the lower shell parallel to the connecting axis (298) of the upper shell (188) and the lower shell (190). Projecting outwardly from (286) with respect to the channel (166),
The first strap (218) is cantilevered and defines an opening (278) between an inner surface (254) and an outer surface (256), the latching surface (220) being the first strap (218). Electrical connector (104) , which is the distal wall of the opening proximate the free end (302) of the strap of the .   The upper shell (188) has a curved body (202) extending between a first shoulder (272) and a second shoulder (274), the first shoulder and the second shoulder (272). Shoulders engage the corresponding shoulders (294, 292) of the lower shell (190) at the interface (194) and the first strap (218) attaches to the first shoulder. A first disposed adjacent to and extending beyond the first shoulder toward the lower shell, the upper shell extending from an outer surface (216) of the upper shell proximate the second shoulder. Locking surfaces (222) of the lower shell for engaging the corresponding locking surfaces (250) of the first straps (248) of the lower shell to bring the upper shell into contact with the lower shell. The electrical connector (104) of claim 1, coupled to a shell.   The upper shell (188) has the same shape as the lower shell (190), the lower shell having the mating axis (112) parallel to the channel (166). The electrical connector (104) of claim 1, oriented 180 degrees relative to. The lower shell (190) has a curved body (204) extending between a first shoulder (292) and a second shoulder (294), the first stop surface of the lower shell (190). (284) extends from the outer surface (246) of the lower shell proximate to the second shoulder, the first stop surface located along a planar region (286) of the outer surface,
Said first stop surface (284) is therefore defined by the hook surface of the tab (296) projecting outwardly from said outer surface to said channel (166), the electrical connector according to claim 1 ( 104).   The cavity insert (138) extends between a front end (264) and a rear end (266), and the first strap (218A) of the upper shell (188) is proximate the front end of the cavity insert. Disposed above the upper shell, the upper shell further comprising a second strap (218B) proximate the rear end of the cavity insert, the second strap extending across the interface (194), The electrical connector (104) of claim 1, wherein the second strap includes a latching surface (220) that engages a corresponding second locking surface (284B) of the lower shell (190).   The middle portion (156) of the outer contact (136) includes a protrusion (260) extending radially outwardly from the middle portion and the cavity insert (138) defines the cavity (166). A recess (262) is defined along an inner surface (244) of the insert (138), the protrusion being received within the recess when the upper shell (188) and the lower shell (190) are joined together. The electrical connector (104) of claim 1, wherein the outer contact is secured within the cavity insert.   The upper shell (188) has a curved body (202) extending between a first edge (206) and a second edge (208), the first edge and the second edge. An edge of the cavity insert (138) extends between a front end (264) and a rear end (266) of the cavity insert (138), the upper shell extending from the first edge. A plurality of straps (218) projecting across the interface (194), the straps being spaced along the length of the cavity insert, the straps corresponding to the lower shell (190). A plurality of tabs (224) extending from an outer surface (216) of the upper shell including a latching surface (220) that engages a retaining surface (284) that is proximate to the second edge. To Further including the tabs of the upper shell spaced apart along the length of the cavity insert, the tabs of the upper shell each engaging a corresponding strap (248) of the lower shell. The electrical connector (104) of claim 1, including a hook surface (222).   The electrical connector (104) of claim 1, wherein the upper shell (188) and the lower shell (190) have an integral body (202, 204).

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